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STANDBY GENERATOR
OWNER'S MANUAL
Not intended for use in critical life support applications.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
0G9425
No.
Part
A new standard of reliability
—CAUTION—
2.4L
22/27kW
Models
This manual should remain with the unit.
06/08
A
Rev.
Cover131
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Table of Contents
Related Manuals for Carrier 2.4L
Summary of Contents for Carrier 2.4L
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Page 1: Serial Number
2.4L Serial Number 22/27kW Models STANDBY GENERATOR OWNER'S MANUAL A new standard of reliability Not intended for use in critical life support applications. —CAUTION— ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! This manual should remain with the unit. -
Page 2: Table Of Contents
Coolant Heater Kit ............6-2 Check Fan Belt ............10-2 Reconfiguring the Fuel System ........6-2 Inspect Engine Governor ........10-3 2.4L Ignition Module Description .........6-3 Changing Engine Oil ..........10-3 Fuel Select Connector ..........6-3 Changing the Engine Air Filter ........10-3 Diagnostic Blink Patterns (Red LED Located Spark Plugs ............10-3... -
Page 3: Introduction
Standby Emergency Generator Important Safety Instructions SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. INTRODUCTION ... -
Page 4: Safety Rules
Standby Emergency Generator Important Safety Instructions WARNING: GENERAL HAZARDS The engine exhaust from this product • For safety reasons, the manufacturer recommends contains chemicals known to the state that this equipment be installed, serviced and of California to cause cancer, birth repaired by a Service Dealer or other competent, defects or other reproductive harm. -
Page 5: Fire Hazards
Standby Emergency Generator Important Safety Instructions • Before performing any maintenance on the gen- • Stationary emergency generators installed with erator, disconnect its battery cables to prevent an automatic transfer switch will crank and start accidental start-up. Disconnect the cable from the automatically when normal (utility) source volt- battery post indicated by a NEGATIVE, NEG or (–) age is removed or is below an acceptable preset... -
Page 6: Identification Record
Stationary Emergency Generator General Information IDENTIFICATION RECORD NOTE: For actual information related to this particular DATA LABEL model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data Every generator set has a DATA LABEL that contains label affixed to the unit. -
Page 7: Equipment Description
Standby Generator Sets Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating cur- Use a mixture of half low silicate ethylene glycol rent generator set. It is powered by a gaseous fueled base anti-freeze and deionized water. Cooling system engine operating at 1800 rpm for 4-pole direct drive capacity is listed in the specifications. -
Page 8: Engine Protective Devices
Stationary Emergency Generator Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The Stationary Emergency Generator may be required After a prespecified duration of cranking, this func- to operate for long periods of time without an opera- tion ends the cranking if the engine has failed to tor on hand to monitor such engine conditions as start. -
Page 9: Fuel Systems
Stationary Emergency Generator Fuel Systems FUEL SYSTEM PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above FUEL REQUIREMENTS the liquid fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel The Stationary Emergency Generator may be equipped expansion from the liquid to the vapor state. -
Page 10: Specifications
Standby Generator Sets Specifications SPECIFICATIONS COOLING SYSTEM Type ...........Pressurized Closed Recovery GENERATOR Water Pump ..............Belt Driven Type ................Synchronous Fan Speed .................1980 rpm Rotor Insulation ..............Class H Fan Diameter ..........460 mm (18-1/8 inches) Stator Insulation ..............Class H Fan Mode ................Pusher Total Harmonic Distortion ............<5% Air Flow (inlet air including alternator and... -
Page 11: Cold Weather Kit
Standby Generator Sets Specifications Figure 6.1 — Interconnections Utility In Transfer Switch NEUTRAL Load 4- # 14 GA WIRES TO GENERATOR CONNECTION TO GENERATOR CONNECTION BOX To Generator Control Panel This is a generic representation of the components contained in the transfer switch and connection box. Refer to the wiring and schematic diagrams for generator specifi... -
Page 12: L Ignition Module Description
(1) minute. IGNITION MODULE DESCRIPTION Ignition Module (P/N 0G8876) operates with a 4-cylin- der, 2.4L, 22kW or 27kW, 1800rpm engine and uses ENGINE HARNESS the same flywheel mag pick-up signal as the R-200B controller. - Page 13 Standby Generator Sets Specifications 3. No Flywheel Signal — LED blinks two (2) times, is OFF for three (3) seconds and then repeats. 4. No Cam Signal — LED blinks three (3) times, is OFF for three (3) seconds and then repeats. Only one LED fault code is displayed at a time.
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Page 14: General Information
Standby Generator Sets General Information GENERATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING See “Voltage Codes”. This generator may be rated CONNECTIONS at any one of three voltages, either single-phase or three-phase. The electrical wires in the unit’s AC con- 3-PHASE ALTERNATORS nection (lower) panel should be installed according to the number of leads and the voltage/phase required The generator is designed to supply 3-phase electri-... -
Page 15: Installation
Stationary Emergency Generator Installation INSTALLATION NOTE: Refer to the separate “Installation Guide” supplied This engine is shipped from the manufacturer with the unit. with “break-in” oil. This oil should be changed after 30 hours of operation. For safety reasons, the manufacturer recommends that this equipment be installed, serviced and PRIOR TO INITIAL START-UP repaired by a Service Dealer or other competent,... -
Page 16: Start-Up Checklist
Stationary Emergency Generator Installation • Correct AC and DC wire size, connections and • Verify the AUTO/OFF/MANUAL switch is in OFF grounding. Control and communication wiring to/ position. from the transfer switch must be run in a separate • Open the valve to the engine fuel line. conduit from the AC power leads. -
Page 17: Operation
Stationary Emergency Generator Operation STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION Do not crank the engine continuously for longer Refer to the appropriate control panel operator’s than 30 seconds, or the heat may manual for this unit. damage the starter motor. •... -
Page 18: Maintenance
Standby Generator Sets Maintenance MAINTENANCE PERFORMED BY COOLING SYSTEM Air intake and outlet openings in the generator com- SERVICE FACILITIES partment must be open and unobstructed for contin- ued proper operation. This includes such obstruc- tions as high grass, weeds, brush, leaves and snow. ... -
Page 19: Battery Fluid
Standby Generator Sets Maintenance EXERCISE SYSTEM • Remove oil dipstick and wipe dry with a clean, lint- free cloth. Start the generator engine at least once every seven • Install oil dipstick, then remove again. days and let it run at least 20 minutes. For more •... -
Page 20: Inspect Engine Governor
Standby Generator Sets Maintenance INSPECT ENGINE GOVERNOR Visually inspect electronic governor. After refilling the crankcase with oil, always DANGER check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK “ADD” Do not attempt to adjust the governor. Only MARK. -
Page 21: Coolant Change
Standby Generator Sets Maintenance Figure 10.5 – Setting the Spark Plug Gap • Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns. DO SET PLUG GAP AT 1.07 - 1.17 mm NOT permit fluid to contact eyes, skin, clothing, (0.042 - 0.046 inch) painted surfaces, wiring insulation, etc. -
Page 22: Battery Replacement
Standby Generator Sets Maintenance REPAIR PARTS The later portion of this manuals consists of exploded views, parts lists and electrical data pertaining to this Be sure the AUTO/OFF/MANUAL switch is set to generator set. The parts list consists of: (a) an Item the OFF position, before connecting the battery Number, (b) a Part Number, (c) Quantity required, cables. -
Page 23: Service Schedule
Standby Generator Sets Service Schedule SERVICE SCHEDULE 30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. - Page 24 Standby Generator Sets Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
- Page 25 Standby Generator Sets Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
- Page 26 Standby Generator Sets Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
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Page 27: Troubleshooting
Stationary Emergency Generator Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defective 2. Tighten, clean or replace battery cables. battery cables as necessary. 3. Defective starter contactor. 3. - Page 29 0G8827A STUD M8-1.25 418 LONG (22KW) 0A9375 SCREW RHM #10-24 X 2 022152 WASHER LOCK #10 0G8311 FLYWHEEL & RINGGEAR ASSY 2.4L 042558 KEY SQ 3/8 X 1 STEEL (1) 18 051756 SCREW HHC M10-1.5 X 20 C8.8 0G8364 PLATE FLEX 2.4L 10" ALT...
- Page 31 NUT HEX M5-0.8 G8 CLEAR ZINC 049813 NUT HEX M6 X 1.0 G8 YEL CHR 0E3257 SCREW HWHTF M6-1.0 X 16 0G8876 ASSY PCB IGN MOD 2.4L NO-TURBO (2.4L ONLY) 048766 BLOCK TERM 20A 2 X 6 X 1100V 0G7991 DECAL GTS CUSTOMER CONNECTION 036943 SCREW PPHM #10/32 X 2 (2.4L ONLY)
- Page 33 UL BREAKER ED UL BREAKER 0D5548 CB 0030A 3P 480V S ED4 LL 0G5249 CB 150A 2 POLE 240V 225AF 0D5549 CB 0035A 3P 480V S ED4 LL W/CB TERMINAL COVER CB 0D5551 CB 0045A 3P 480V S ED4 LL 0G5735 CB COVER 30K G 225AF 0D5552...
- Page 35 0G83760ST03 MOUNTING BASE 2.4L 027482 WASHER SHAKEPROOF EXT 5/16 STL 070936 DAMPENER VIBRATION 070936C VIB. ISO. 70-75 DURO 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16 ZINC 022129 WASHER LOCK M8-5/16 045771 NUT HEX M8-1.25 G8 YEL CHR...
- Page 37 0F3408C BATTERY TRAY, C1 & C2 0F3411 STRAP BATTERY RETAINMENT 025507 WASHER SHAKEPROOF EXT 7/16 STL 052212 SCREW HHC M10-1.25 X 25 C8.8 046526 WASHER LOCK M10 077483 BATTERY 12VDC 75-AH 26 (SOLD AS AN OPTION) 050331A BATTERY POST COVER RED + 050331 BATTERY POST COVER BLK - 038805J...
- Page 40 029333A TIE WRAP UL 7.4"X .19" BLK 047290 HOSE 3/8 ID SINGLE BRAID (15” LG) 0G8877 HARN ENG 2.4L R-200B 1800 NO-T (NOT SHOWN) 069860B HOSE OIL DRAIN ASSY 16" 063076 7 (REF) WASHER FLAT .531 ID X 1.062 OD 0C7649 CLAMP HOSE .38-.87...
- Page 43 HOSE LOWER RADIATOR 2.4L 0G81290GS0R BLOCK OFF RADIATOR 2.4L 0F9504 GROMMET 5/8"X 1 1/8"X 5/16" 0G81280GS0R SUPPORT RADIATOR RH SIDE 2.4L 0G81260GS0R VENTURI 2.4L 0C2454A SCREW THF M6-1 X 12 N WA Z/JS 042568 SCREW HHC M6-1.0 X 20 G8.8...
- Page 45 037561 NUT WING 1/4-20 NYLK 0A5547 COVER AIR CLEANER 062522 STUD TH 1/4-20 X 3 G2 ZNC FULL 022127 NUT HEX 1/4-20 STEEL 059402 FILTER ELEMENT 091526 SCREW PPHM M5-0.8 X 12 ZNC 049226 WASHER LOCK M5 057823 CLAMP HOSE #10 .56-1.06 047290 HOSE 3/8 ID SINGLE BRAID (15”...
- Page 49 0F7366 MUFFLER C1 0F7647 MUFFLER SADDLE 0F8095 PIPE EXHAUST OUTLET 0G8614 EXHAUST ELBOW 2.4L G2 0E3257 SCREW HWHTF M6-1.0 X 16 0F7644 MUFFLER STRAP 0C6119 BOLT U 5/16-18 X 2-1/4 036434 BOLT U 5/16-18 X 2.09 036449 SADDLE 2 INCH...
- Page 57 NUT HEX M3-0.5 G8 YEL CHR 0F3192 SUPPORT ANGLE PCB 0E7403C FUSE ATO TYPE 15 AMP (BLUE) 0G9056 HARN CTRL PNL R-200B 2.4L/4.2L (NOT SHOWN) COMPONENTS INSTALLED PER THIS DRAWING 056739 RELAY SOLENOID 12VDC PNL MNT 022287 SCREW HHC 1/4-20 X 3/4 G5...
- Page 64 Catalog No:OMASPFY022---027A ---01 Copyright 2009 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 02/09 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Replaces: NEW...